Method and apparatus for casting lenses

ABSTRACT

An apparatus for manufacturing a lens with a predetermined prescription from a number of lens molds, a gasket, and a source of a fluid material. The apparatus includes a device for selecting a first lens mold and a second lens mold based upon the prescription, a device for positioning the lens molds within the gasket, a device for inserting an amount of the fluid material within the gasket and between the molds, a device for curing the fluid material so as to form the lens, and a device for advancing the lens molds along a predetermined path through the selecting device, the positioning device, the fill device, and the cure device.

FIELD OF THE INVENTION

[0001] The present invention relates generally to an automatedmanufacturing system and more particularly relates to a method and anapparatus for manufacturing optical lenses to order in an efficient,high-speed manner.

BACKGROUND OF THE INVENTION

[0002] The traditional manufacturing and distribution chain for a lensused in consumer eyeglasses generally includes a manufacturer, alaboratory, and a retail outlet. The manufacturer typically makes a lensblank and then ships the blank to the laboratory. The blank is anunfinished lens. The laboratory generally surfaces and edges the lens inthe appropriate fashion for a given prescription and then ships the lensto the retail outlet. The retail outlet cuts and fits the lens to theappropriate frame. The retail outlet is generally a doctor or an eyecare outlet. The retail outlet both orders the lens from the laboratoryor the manufacturer and then fits the lens and the frame as appropriatefor the consumer.

[0003] Any of the parties in the manufacturing and distribution chainmay stockpile certain types of lenses. Certain common prescriptions maybe manufactured in bulk and kept in supply. In most cases, these lensesare single vision lenses, i.e., lenses with only one viewing power.Other types of prescriptions, however, may not be as common and may bemade only on an as-needed basis. Further, other types of lenses, such asprogressive lenses (bi-focal lenses without lines) are generally made ondemand given the differing strengths involved in the single lens. Inother words, the progressive lens will have surfaces of differentcurvature as required for distance and reading.

[0004] These specialty lenses generally are more expensive in that themanufacturing process is both time and labor intensive. Further, theselenses cannot be easily inventoried because of the multiple permutationsof strengths in a given lens. This is particularly due to the conditionof astigmatism. Astigmatism requires the proper orientation of a toriccurve on the back of the lens relative to the eye. Because theadditional power cylinder also must align properly, it is not practicalto maintain an inventory of multi-focal lenses. Multi-focal lensestherefore generally are produced by grinding and polishing asemi-finished blank.

[0005] Competition in this segment of the lens manufacturing anddistribution market is largely based on the ability to producehigh-quality specialty lenses while attempting to minimize the time andlabor involved. There is a need, therefore, for a flexible, high-speedspecialty lens manufacturing process that can produce lenses in anefficient manner.

SUMMARY OF THE INVENTION

[0006] The present invention thus provides an apparatus formanufacturing a lens with a predetermined prescription from a number oflens molds, a gasket, and a source of a fluid material. The apparatusincludes a means for selecting a first lens mold and a second lens moldbased upon the prescription, a means for positioning the lens moldswithin the gasket, a means for inserting an amount of the fluid materialwithin the gasket and between the molds, a means for curing the fluidmaterial so as to form the lens, and a means for advancing the lensmolds along a predetermined path through the selecting means, thepositioning means, the fill means, and the cure means. The apparatusalso may include a control system for operating the selecting means, thepositioning means, the fill means, and the cure means.

[0007] Specific embodiments of the present invention may include the useof a personal computer with the control system. The control systemfurther may include a database and a data input and output means.

[0008] The selecting means may include a conveyor advancing along thepredetermined path with one or more transport pallets positionedthereon. The selecting means also may include a storage carousel forstoring the lens molds and an automated access arm for transporting thelens molds from the storage carousel to the pallet on the conveyor. Theaccess arm may be a pick and place arm. The access arm may include agantry, a number of gripper heads, and a number of gripper arms forgripping the lens molds. Each of the gripper heads may include anoptical device for reading the indicator. The optical device may includea fiber optic sensor. The fiber optic sensor confirms that the lens moldis in the gripper arms.

[0009] The positioning means may include a positioning station with anoptical device. The lens molds may have a tic mark or a positioning markthereon. The optical device may be a camera-based vision system so as toview the tic mark positioned on the lens molds. The optical device maybe positioned within a positioning stage. The positioning stage mayrotate the lens molds according to the viewed position of the tic mark.The positioning means also may include an assembly station with aretractable assembly stage positioned within a gasket mount. Theassembly stage inserts the first lens mold within the gasket at apredetermined depth and then inserts the second lens mold within thegasket at a second predetermined depth. The positioning means also mayinclude a gasket supply with a number of the gaskets.

[0010] The positioning means may include one or more access arms formaneuvering the first lens mold, the second lens mold, and the gaskettherethrough. A first access arm may position the lens molds on thepositioning station, a second access arm may maneuver the lens moldsbetween the positioning station and the assembly station, and a thirdaccess arm may maneuver the gasket between the gasket supply and theassembly station and also remove the lens molds and the gasket from theassembly station. The access arms may move along a gantry. Each accessarm may have a pair of gripper arms for gripping the lens molds and thegasket.

[0011] The inserting means may include one or more fill stations with aneedle for piercing the gasket and a variable speed pump for deliveringthe fluid material. The inserting means also may include one or morecure stations with one or more radiation sources. The radiation sourcesmay be ultraviolet light or visible light sources. Shutters may coverthe radiation sources. The shutters may operate independently of oneanother to provide variable cure cycles from the front and the back.

[0012] The present invention may further include a means for removingthe lens and the lens mold from the gasket. The removing means mayinclude a pair of movable degasketing arms for stretching the gasket andan extendable plunger for pushing the lens and the lens molds out of thegasket. The invention may further include a means for separating thelens and the lens mold via a number of heating and cooling stations. Theinvention may further include a means for coating the lens with ascratch resistant treatment, a means for verifying the prescription ofthe lens, and a means for cleaning the lens molds.

[0013] A further embodiment of the present invention may provide adevice for identifying and orienting a lens mold as the mold advancesalong a conveyor positioned along a predetermined path. The lens moldmay have an identification indicator thereon and a positioning markthereon. The device may include an access arm to grasp the lens mold, anoptical device to read the identification indicator and the positioningmark, and a printer to print a further indicator on the lens mold at apredetermined location thereon. The device may further include a controlsystem for controlling the access arm, the optical device, and theprinter. The optical device may include a bar code reader to read theindicator and a camera-based vision system to view the positioning mark.Alternatively, the bar code could be read by the camera-based visionsystem. The access arm includes one or more gripper arms such that thegripper arms can grasp and rotate the lens mold. The printer may be anink jet printer.

[0014] The method of the present invention provides a method formanufacturing a lens with a predetermined prescription from a number oflens molds, a gasket, and a source of a fluid material. The methodincludes the steps of selecting a first mold and a second mold basedupon the predetermined prescription, advancing the first lens mold alonga predetermined path, positioning the first lens mold within the gasket,advancing the second lens mold along the predetermined path, positioningthe second lens mold within the gasket, advancing the first lens mold,the second lens mold, and the gasket along the predetermined path,inserting a predetermined amount of the fluid material within the gasketand between the lens molds, and curing the fluid material so as to formthe lens based upon the predetermined prescription.

[0015] A further embodiment of the present invention provides a storageand retrieval station for use with a number of lens molds for makinglenses. The storage and retrieval station may have a control system, aconveyor controlled by the control system, a storage rack for storingthe lens molds positioned adjacent to the conveyor, and an access armcontrolled by the control system for transporting a predetermined lensmold from the storage rack to the conveyor. The access arm may have anoptical device thereon so as to confirm that the access arm has pickedup one of the lens mold from the storage rack. The storage rack mayinclude a rotatable storage carousel. The control system controls therotatable storage carousel in coordination with the access arm. Theaccess arm may include a gantry, a gripper head, and a pair of gripperarms so as to acquire the predetermined lens mold. The optical devicemay include a fiber optic sensor.

[0016] A further embodiment of the present invention provides anassembly apparatus for positioning a first lens mold and a second lensmold into a gasket so as to form a lens of a predetermined prescription.The lens molds each may include a positioning mark thereon. Theapparatus may further include an positioning station for detecting thepositioning mark, a gasket supply with the gasket therein, an assemblystation for positioning the first lens mold and the second lens moldwithin the gasket, and an access arm system for transporting the firstlens mold, the second lens mold, and the gasket along the predeterminedpath. The assembly apparatus further may include a control system foroperating the positioning station, the assembly station, and the accessarm system.

[0017] The positioning station may include an optical device for viewingthe positioning mark on the lens mold. The optical device may include acamera-based vision system. The positioning station also may include apositioning stage surrounding the optical device. The positioningstation may rotate the lens molds as directed by the control systembased upon the view of the positioning mark.

[0018] The assembly station may include a gasket mount sized to supportthe gasket and an assembly stage positioned within the gasket mount. Theassembly stage may position the first lens mold and the second lens moldinto the gasket at a depth as determined by the control system. Thepositioning of the molds may be based upon the predeterminedprescription. The access arm system may include a gantry and a number ofaccess arms. The first access arm may position the lens molds on thepositioning station, the second access arm may maneuver the lens moldsbetween the positioning station and the assembly station, and the thirdaccess arm may maneuver the gasket between the gasket supply and theassembly station and also may remove the lens molds and the gasket fromthe assembly station. Each of the access arms may include a number ofgripper arms to grip the lens molds and the gasket.

[0019] A further embodiment of the present invention may include adevice for filling a mold with a fluid material and curing the fluidmaterial. The device may include a fill station with a pump and aninsertion device and a cure station with a number of radiation sourcesand a number of shutters. Each of the shutters may operate independentlyof one another. A control system may control the fill station and thecure station. The insertion device may include a non-coring needle. Thepump may include a multispeed positive displacement pump. The radiationsources may be ultraviolet light sources, visible light sources, orinfrared light sources. A movable bracket may maneuver the molds betweenthe fill station and the cure station.

[0020] A further embodiment of the present invention may provide adevice for removing a gasket from around a mold. The gasket may have anumber of support brackets. The device may have a plunger capable ofmovement in a first direction and a number of degasketing armssurrounding the plunger. The degasketing arms may be capable of movementin a second direction. The degasketing arms may include a number ofgripper arms to grip the support brackets of the gasket such that thedegasketing arms stretch the gasket in the second direction while theplunger forces the mold out of the gasket in the first direction. Thedevice may further include a control system for controlling the plunger,the degasketing arms, and the gripper arms. An access arm may remove themold from the plunger.

[0021] Other objects, features, and advantages of the present inventionwill become apparent upon reading the following detailed description ofthe invention when taken in conjunction with the drawings and theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022]FIG. 1 is a flow chart showing the steps and stations of thepresent invention.

[0023]FIG. 2 is a schematic diagram of the control system of the presentinvention.

[0024]FIG. 3 is a top plan view of the storage and retrieval station ofthe present invention.

[0025]FIG. 4 is a side plan view of the storage and retrieval station.

[0026]FIG. 5 is a perspective view of the access arm placing a lens moldinto a pallet for transport within the storage and retrieval station.

[0027]FIG. 6 is a perspective view of a lens mold with the indicator andthe tic mark.

[0028]FIG. 7 is a side plan view of the pre-orient and identificationstation.

[0029]FIG. 8 is a top plan view of the positioning and assembly stationof the present invention.

[0030]FIG. 9 is a side plan view of the positioning and assemblystation.

[0031]FIG. 10 is a perspective view of the positioning and assemblystation.

[0032]FIG. 11 is a top plan view of the gasket used in the presentinvention.

[0033]FIG. 12 is a side cross-sectional view of the gasket.

[0034]FIG. 13 is a perspective view of the fill and cure station of thepresent invention.

[0035]FIG. 14 is a side plan view of the fill and cure station.

[0036]FIG. 15 is a side cross-sectional view of the fill and curemodule.

[0037]FIG. 16 is a side plan view of the gasket bracket for use in thefill and cure module.

[0038]FIG. 17 is a top plan view of the degasketing station of thepresent invention.

[0039]FIG. 18 is a side plan view of the degasketing station.

[0040]FIG. 19 is a perspective view of the degasketing station.

[0041]FIG. 20 is a perspective view of the demolding and station of thepresent invention.

[0042]FIG. 21 is a top plan view of the demolding and finishing station.

[0043]FIG. 22 is a perspective view of the lens as manufactured in thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

[0044] Referring now to the drawings in which like numbers refer to likeparts throughout the several views, FIGS. 1 through 21 shown anautomatic casting system 100 of the present invention. The automaticcasting system 100 includes a number of different stations or steps inthe overall casting process. FIG. 1 is a high-level flow chart showingthe steps involved in the manufacture of a lens 110. Each step in theflow chart represents a different station in the automatic lens castingsystem 100 as a whole. As is shown, the automatic casting system 100 mayinclude, but is not limited to, a control system 120, a storage andretrieval station 130, a pre-orient and print station 135, anpositioning and assembly station 140, a fill and cure station 150, adegasketing station 160, and a demolding and finishing station 170. Eachof these steps and stations will be described in more detail below.

[0045] The Control System

[0046] The control system 120 contains information on the manufacture ofmillions of different lens prescriptions. As is described in more detailbelow, the control system 120 selects the appropriate lens molds andalso determines a number of other manufacturing parameters required forthe desired prescription. As is shown in FIG. 2, the control system 120may include a conventional personal computer 180 as well as one or moreprogrammable logic controllers 185. Alternatively, other types ofconventional control devices may be used. The personal computer 180sets, monitors, and controls the various stations of the system 100 as awhole. Preferably, the personal computer 180 may be programmed bysoftware running on the QNX operating system or by similar types ofsoftware. The QNX operating system is a real-time, multitaskingoperating system that is UNIX compatible. For example, the AART softwareor the Flastflex software provided by Advanced Automation of Greenville,South Carolina may be used.

[0047] The control system 120 preferably includes at least one dataentry station 190 with a monitor 200 and a keyboard 210 or other typesof conventional data input/output devices. A conventional database 220also may be provided. The manufacturing parameters for each lens 110prescription may be found in the database 220 or the parameters may beencoded on each mold as described in more detail below.

[0048] The Storage and Retrieval Station

[0049] The storage and retrieval station 130 is positioned along apredetermined path P within the system 100. The predetermined path. P isthe path taken through each of the stations in the system 100 as awhole. As is shown in FIGS. 3-5, the storage and retrieval system 130includes a conveyor system 230 with a conventional conveyor belt or asimilar type of driven advancement system. The conveyor system 230advances along the predetermined path P. Positioned on the conveyorsystem 230 may be one or more pallets 240. Each pallet 240 preferablyhas two lens mold storage basins 250. A first lens mold 260 may bepositioned within a first basin 270 and a second lens mold 280 may bepositioned within a second basin 290. The pallet 240 may have a radiofrequency tag 295 thereon so as to identify and track the pallet 240 asit travels through the system 100. The pallet 240 may be made out of anyconventional non-metallic material so as to minimize or eliminate anyscratches or damage to the lens molds 260, 280. The pallet 240 also maybe anti-static to avoid the accumulation of dust. The lens molds 260,280 are generally made out of glass, plastic, or other known types ofcasting materials. Each pair of the lens molds 260, 280 combine toprovide a lens 110 of a given prescription.

[0050] The storage and retrieval system 130 further includes a storagecarousel 300 for storing a plurality of the lens molds 260, 280. Thestorage carousel 300 is preferably a circular structure with a number oftrays 320 mounted on a central spindle 330. The storage carousel 300 maybe motorized so as to rotate about the central spindle 330. Rotation ofthe storage carousel 300 is controlled by the control system 120.Positioned on each of the trays 320 may be a plurality of mold storagelocations 340. Each of the plurality of the lens molds 260, 280 isstored in these locations 340.

[0051] The carousel 300 cooperates with an automated access arm 350 or a“pick and place” arm. The access arm 350, as described here and below,preferably is as multiple axes, servomotor driven robotic arm. Theaccess arm 350, however, also may be operated by electrical, pneumatic,or mechanical means as is known to those skilled in the art. A preferredaccess arm 350 may use one or more linear servos manufactured by NSKLtd. of Tokyo, Japan. The access arm 350 is positioned on a verticalgantry 360. The access arm 350 includes at least two gripper heads 370,a first gripper head 380 and a second gripper head 390. The gripperheads 370 may include a pair of gripper arms 400. The gripper arms 400are capable of reciprocating motion so as to pick up and drop off one ofthe plurality of lens molds 260, 280. The access arm 350 is capable ofmovement in at least two axes. The access arm 350 may rotate about thegantry 360 in the horizontal plane and also move up and down the gantry360 in the vertical plane. The movement of the access arm 350 iscontrolled by the control system 120. Each of the gripper heads 370 alsomay includes an optical device 420 such as a fiber optic sensor or othertypes of conventional recognition devices.

[0052] The control system coordinates movement of the conveyor 230, thecarousel 300, the access arm 350, and the gripper arms 400 such that aspecific lens mold 260, 280 may be removed from its mold storagelocation 340 on the carousel 300 by the access arm 350 and placed in thecorrect basin 270, 290 of the pallet 240. The first gripper head 380 mayremove one of the lens molds 260, 280 from the pallet 240 for return tothe storage carousel 300 while the second gripper head 390 placesanother of the lens molds 260, 280 on the pallet 240. The optical device420 ensures that a lens mold 260, 280 is in fact in position within thegripper arms 400 before the access arm 400 proceeds.

[0053] The control system 120 remembers which lens mold 260, 280 ispositioned within which mold storage location 340 on the carousel 300.It is not necessary to have the lens molds 260, 280 assigned to aspecific position within the mold storage location 340. Rather, thecontrol system 120 tracks where each lens mold 260, 280 is placed. Thecontrol system 120 also can track information such as the number of usesfor a mold 260, 280 or which specified molds 260, 280 were used to makea given lens 110. Also easily tracked is the distribution ofprescriptions, the lifetime of certain mold geometries, which is helpfulfor ordering replacement molds 260, 280, and other types of useinformation. Each lens mold 260, 280 may have a unique identificationnumber that is unrelated to its geometry for tracking purposes.

[0054] Pre-Orient and Print Station

[0055] The pallet 240 with the lens molds 260, 280 therein then continuedown the conveyor system 230 along the predetermined path P to thepre-orient and print station 135. The lens molds 260, 280 positioned onthe pallet 240 may be identified by the radio frequency tag 295.Likewise, the expected prescription also may be identified by the tag295. Each of the plurality of the lens molds 260, 280 may have anindicator 430 positioned thereon. The indicator 430 may take the form ofa bar code and/or a humanly readable legend. The indicator 430 mayidentify the particular lens mold 260, 280 to the control system 120 andmay further provide information on the nature of the lens mold 260, 280such as its prescription information and manufacturing parameters. Oneor more tic marks 265 also may be present on the lens molds 260, 280 soas to determine the orientation of the mold 260, 280. FIG. 6 shows aperspective view of the lens mold 260 with the indicator 430 and the ticmarks 265.

[0056] The pre-orient and print station 135 is shown in FIG. 7. Thepre-orient and print station 135 is positioned across the conveyor 230and includes an access arm 440 that is positioned upon a gantry 441. Theaccess arm 440 may have an extendable cylinder 442 so as to extend andretract in the vertical direction and a number of gripper arms 443 tograb and release the lens molds 260, 280. The gripper arms 443 mayoperate largely in the horizontal plane so as to grab the lens molds260, 280 from the pallet 240. The gripper arms 443 also may be capableof rotating the lens molds 260, 280 to a desired orientation. The accessarm 440 is controlled by the control system 120.

[0057] The access arm 440 also may include an optical device 444 and aprinter 445 positioned thereon. The optical device 444 may included abarcode reader 446 or a similar type of optical recognition deviceand/or a vision system 447 such as a camera-based recognition device.The printer 445 may take the form an inkjet printer or a similar device.The printer 445 may print a further indicator 448 on one of the lensmolds 260, 280.

[0058] As the pallet 240 reaches the pre-orient and print station 135,the extendable cylinder 442 of the access arm 440 extends downward. Thegripper arms 443 grasp the first lens mold 260 and remove it from thepallet 240. The bar code reader 446 of the optical device 444 positionedon the access arm 440 reads the indicator 430 on the lens mold 260 toinform the control system 120 that the correct mold 260 is present. Thebar code reader 446 also may obtain the manufacturing parameters fromthe indicator 430. The access arm 440 returns the first lens mold 260 tothe pallet 240 and then removes the second lens mold 280. The bar codereader 446 again reads the indicator 430 thereon and informs the controlsystem 120 that the correct mold 280 is present. Again, the opticaldevice 444 also may obtain the manufacturing parameters from theindicator 430.

[0059] The vision system 447 of the optical device 444 also may view thetic marks 265 on the lens molds 260, 280 to determine their location andthe orientation of the lens molds 260, 280. Alternatively, the bar codecould be read by the camera-based vision system. The gripper arms 443,under the control of the control system 120, then may rotate the lensmolds 260, 280 to prepare them for printing. The purpose of orientingthe lens molds 260, 280 is to have the further indicator 448 printed onthe “top” of the mold 260, 280 such that when the further indicator 444is transferred to the lens 110, the further indicator 448 is likely in alocation that will be ground off when the lens 110 is fitted to theconsumer's frame. The further indicator is generally printed on thesecond lens mold 280. The gripper arms 443 thus rotate the lens mold 280based upon the position of the tic marks 265 as viewed by the visionsystem 447.

[0060] Once the gripper arms 443 have rotated the lens mold 280, theprinter 445 is activated. The ink used with the printer 445 is selectedto allow the further indicator 448 to remain on the lens mold 280 atleast through the curing process. The ink preferably has a strongaffinity for a polymeric lens material such that the further indicator448 is transferred to the lens 110. The further indicator 448 may takethe form of a machine-readable barcode and/or humanly readable digits,graphics, letters, or any combination thereof. A preferred markingprocess is described in U.S. patent application Ser. No. 09/409,318entitled “Method of Inventory Control from Molded Lenses”. The furtherindicator 448 also may be printed on the first lens mold 260 if desired.After printing, the access arm 440 returns the second lens mold 280 tothe pallet 240.

[0061] The Positioning and Assembly Station

[0062] The pallet 240 with the lens molds 260, 280 therein thencontinues down the conveyor system 230 along the predetermined path P tothe automated positioning and assembly station 140. The automatedpositioning and assembly station 140 is shown in FIGS. 8-10. The station140 may include a positioning station 450, an assembly station 460, anda gasket supply 470 with a plurality of gaskets 475. The same gasket 475in terms of shape, size, and materials is used herein for eachprescription. The positioning station 450 may include a positioningstage 480 surrounding an optical device 485. The optical device 485 maybe a vision system such as a camera-based detection or recognitiondevice. The positioning stage 480 may extend and retract in the verticaldirection under the direction of the control system 120. The assemblystation 460 may include a gasket mount 490 surrounding an assembly stage495. The assembly stage 495 also may extend and retract in the verticaldirection within the gasket mount 490 under the direction of the controlsystem 120. The gasket supply 470 may include a conveyor 477 or othertype of device that positions the gaskets 475 in a predeterminedlocation.

[0063] The positioning station 450, the assembly station 460, and thegasket supply 470 are accessed by three automated access arms 500, afirst access arm 501, a second access arm 502, and a third access arm503. The access arms 500 are positioned upon a gantry 510 for movementalong the predetermined path P in a direction largely (but notnecessarily) perpendicular to the direction of the conveyor 230. Thefirst access arm 501 is positioned between the conveyor 230 and thepositioning station 450. The second access arm 502 is positioned betweenthe positioning station 450 and assembly station 460. The third accessarm 503 is positioned between the assembly station 460 and the gasketsupply 470.

[0064] The access arms 500 each may have a number of gripper arms 520 tograb and release the lens molds 260, 280 and the gaskets 475. Thegripper arms 520 may operate largely in the horizontal plane so as tograb the molds 260, 280 and the gaskets 475. The access arms 500 arecontrolled by the control system 120. The access arms 500 may be largelyidentical.

[0065] The first access arm 501 picks up the first lens mold 260 fromthe pallet 240 via the gripper arms 520. The lens molds 260, 280positioned on the pallet 240 may be identified by the radio frequencytag. Likewise, the expected prescription also may be identified by thetag 295. The first access arm 501 travels along the gantry 510 to thepositioning station 450. The positioning stage 480 rises to support thefirst lens mold 260. Once the gripper arms 520 release the lens mold260, the positioning stage 480 then lowers so as to allow the firstaccess arm 501 to return to the pallet 240 to pick up the second lensmold 280. The optical device 485 detects the tic marks 260 on the lensmold 260 such that the stage 480 may rotate the lens mold 260 under thedirection of the control system 120 to ensure that the mold 260 isproperly oriented. FIG. 6 shows a perspective view of the lens mold 260with the indicator 430 and the tic mark 265 being viewed by the opticaldevice 485.

[0066] Once the lens mold 260 has been inspected by the optical device485 and positioned by the positioning stage 480, the second access arm502 moves into position over the positioning station 450. Thepositioning stage 480 again rises and allows the first lens mold 260 tobe captured by the gripper arms 520. The positioning stage 480 lowersand allows the second access arm 502 to travel to the assembly station460. The assembly stage 495 rises to support the first lens mold 260such that the gripper arms 520 may release the lens mold 260 onto theassembly stage 495. The assembly stage 495 then retracts within thegasket mount 490 to permit the second access arm 502 to return to thepositioning station 450.

[0067] While the second access arm 502 transports the first lens mold260 to the assembly station 460, the gripper arms 520 of the firstaccess arm 501 grab the second lens mold 280 off of the pallet 240. Thesecond access arm 502 transports the second lens mold 280 to thepositioning station 450 where it is captured, inspected, and positionedin the same manner as described above with respect to the first lensmold 260.

[0068] Once the first lens mold 260 is positioned on the assembly stage495 within the gasket mount 490, the gripper arms 520 of the thirdaccess arm 503 pick up a gasket 475 from the gasket supply 470. Thethird access arm 503 places the gasket 475 upon the gasket mount 490 inthe assembly station 460. The assembly stage 495 then pushes the firstlens mold 260 into place within the gasket 475 while the gasket 475 isheld in place by the gripper arms 520. The position of the first lensmold 260 within the gasket 475 is determined by the control system 120based upon the indicator 430 and/or the database 220 so as tomanufacture the lens 110 with the desired prescription. The assemblystage 495 then retracts and the third access arm 503 removes the gasket475 with the first lens mold 260 therein. The third access arm 503travels down the gantry 510 a short distance so as to clear the assemblystation 460.

[0069] The second access arm 503 then returns to the positioning station450 to pick up the second lens mold 280. The second access arm 503 thentransports the second lens mold 280 to the assembly stage 495 of theassembly station 460. Once the gripper arms 520 release the second lensmold 280, the assembly stage 495 retracts within the gasket mount 490 soas to allow the second access arm 502 to return to the positioningstation 450. The third assembly arm 503 then repositions the gasket 475with the first lens mold 260 therein back on the gasket mount 490. Thegripper arms 520 of the third access arm 503 keep the gasket 475 inplace as the assembly stage 495 pushes the second lens mold 280 intoplace within the gasket 475. The position of the second lens mold 280within the gasket 475 is determined by the control system 120 based uponthe desired prescription and the geometry of the specific mold.

[0070] The assembly stage 495 then retracts and the third access arm 503transports the gasket 475 with the lens molds 260, 280 therein along thegantry 510 to a gasket pallet 560 positioned on a second conveyor system570 that travels along the predetermined path P. A further method forassembling the lens molds 260, 280 is shown in patent application Ser.No. 09/026,310, entitled “Method and Apparatus for Assembling a LensForming Device”, now allowed and incorporated herein by reference.

[0071] As is shown in FIGS. 11 and 12, the gasket 475 itself isgenerally a circular structure with an outer wall 600 defining an innerbore 610. At least one port 620 is positioned on the outer wall 600 forcommunication with the bore 610. Preferably the ports 620 on the outerwall 600 include a thin septum 630 on one end and an exhaust vent 640positioned on the other end. These ports 630, 640 each may be positionedwithin a support bracket 650. The support brackets 650 may extend beyondthe outer wall 600 and provide a structure for gripping the gasket 475.The gasket 475 itself is preferably made from a thermoplastic rubbercompound or similar materials. A preferred gasket material is sold byThe Thermoplastic Elastomers Division of GLS Corporation under thedesignation Dynaflex G2711 with Krayton G polymers. Another preferredgasket for use in the present application is described in U.S. patentapplication Ser. No. 09/025,903, entitled “Gasket for Lens Making”, nowallowed and incorporated herein by reference.

[0072] The Fill and Cure Station

[0073] The second conveyor 570 then carries the gasket palate 560 to thefill and cure station 150. The fill and cure station 150 is shown inFIGS. 13-16. The fill and cure station 150 includes a number of fill andcure modules 700. In this embodiment, eight (8) fill and cure modules700 are used, modules 701, 702, 703, 704, 705, 706, 707, 708. Any numberof modules 700 may be used. Each fill and cure module 700 has one fillstation 710, a first cure station 720, and second cure station 730. Thefill station 710 may have a pair of clamps positioned therein so as tohold each gasket 475 in place. The fill station 710 also has anon-coring needle 750 positioned therein for insertion into the septum630 of the gasket 475. The needle 750 is in fluid communication with anexternal pump 760 and a source 770 of a polymeric lens material 780. Thepump 760 preferably is a positive displacement pump. The pump 760 may becylindrical in shape and driven by a servomotor, a stepper motor, or asimilar device. The pump 760 also is preferably a multi-speed pump. Thepolymeric lens material 780 preferably is a monomer that is curableunder ultraviolet light. A preferred polymeric lens material 780 may anacrylate oligomer or a similar type of material. Any conventional typeof polymeric lens material 780, however, may be used.

[0074] The cure stations 720, 730 each may have a front ultravioletlight source 790 and a rear ultraviolet light source 800. Alternatively,visible light sources or infrared lights sources may be used.Preferably, ultraviolet light or visible light sources are used. Thefront ultraviolet light source 790 is covered with a front shutter 810while the rear ultraviolet light source 800 is covered with a rearshutter 820. The spacing between the light sources 790, 800 is aboutthree inches. Operations of the light sources 790, 800 and the shutters810, 820 is controlled by the control system 120 depending upon theentered prescription. The shutters 810, 820 may be operatedindependently of one another. The ultraviolet light sources 790, 800preferably can deliver radiation of approximately 1,400 millijoules persquare centimeter of UV energy. At the position of the molds 260, 280,the intensity is between 0.5 and 20 mW/cm². The light sources 790, 800are grid lamps from Jelight Corporation. These are low pressure mercurylamps coated with a phosphor to emit a certain spectra of light. At thepeak wavelength, the intensity is typically between 1 and 5 mW/cm².

[0075] Each fill and cure module 700 may include a movable bracket 840with two (2) gasket holders 850 therein, a first gasket holder 851 and asecond gasket holder 852. The gasket holders 850 are sized to accept andsupport a gasket 475 therein. The bracket 840 maneuvers the individualgasket holders 851, 852 between the fill station 710 and the first andsecond cure stations 720, 730. Positioning of the bracket 840 within themodules 700 is controlled by the control system 120.

[0076] The fill and cure station 150 also includes at least oneautomated access arm 870. The access arm 870 is positioned on a gantry880 for horizontal movement between the second conveyor 570 and the filland cure modules 700. The access arm 870 also may have an extendablecylinder 885 for movement in the vertical direction. The extendablecylinder 885 may, in turn, include a pair of gripper arms 890 forgrabbing and releasing the gasket 475. The extendable cylinder 880 andthe gripper arms 890 are controlled by the control system 120.

[0077] The gripper arms 890 of the access arm 870 remove the gasket 475with the lens molds 260, 280 therein from the gasket pallet 560. Theaccess arm 870 moves along the gantry 880 to one of the fill and curemodules 700. In this example, the access arm 870 places the gasket 475in the first gasket holder 851 of the bracket 840 within first full andcure module 701. At the time, the first gasket holder 851 is positionedwithin the fill station 710. The gasket 475 is positioned in the fillstation 710 with the septum 630 end facing the needle 750. The gasket475 may be held in place within the fill station 710 by a number ofclamps or other means. The needle 790 is inserted into and punctures theseptum 630.

[0078] The pump 760 then pumps the polymeric lens material 780 into thebore 610 of the gasket 475 from the polymeric material source 770. Anyair within the bore 610 is forced out through the exhaust port 640. Therate of fill of the bore 610 is controlled by the control system 120.Early on, the fill rate is slow so as to avoid the encapsulation ofbubbles therein. In the middle, the fill rate is increased to themaximum rate. The rate is again slowed towards the end of the fill so asto prevent overfilling the bore 610. The amount of the polymeric lensmaterial 810 to be inserted within the bore 610 of the gasket 475 iscontrolled by the control system 120. On average, about 15 to 40milliliters of material 810 may be inserted into the bore 610. Eachprescription may have a different flow rate profile as to start, middle,and end rates. After filling is complete, the needle 750 is removed. Theseptum 630 preferably is self-sealing to prevent leakage.

[0079] After the bore 610 is filled and the needle 750 is removed, thebracket 840 slides the first gasket holder 851 with the gasket 475therein either to the right or to the left and into the first or secondcure station 720, 730. Once the gasket holder 851 is in place within thecure station 720, 730, the control system 120 opens the shutters 810,820 so as to expose the polymeric lens material 780 within the bore 610to the ultraviolet radiation. The control system 120 operates the lightsources 790, 800 and the shutter 810, 820 independently such that thefront and rear cure times may vary according to the prescription. Thepolymeric lens material 780 preferably cures in about ten (10) to aboutone hundred eighty (180) seconds. Some materials may take much longer tocure, depending upon the chemistry. The polymeric lens material 780hardens to form the lens 110. As the polymeric lens material 780hardens, the further indicator 448 positioned on the back mold 280transfers onto the lens 110.

[0080] While the polymeric lens material 780 is curing within the firstgasket holder 851 in, for example, the first cure station 720, thesecond gasket holder 852 of the bracket 840 is positioned within thefill station 710. Another gasket 475 maybe positioned therein by theaccess arm 870 and filled in the same manner as described above. Oncethe curing of the gasket 745 in the first cure station 720 is complete,the bracket 840 again shifts the first gasket holder 851 into the middlefill station 720 position. In doing so, the second gasket holder 852 ismoved into the second cure station 730 for the curing process. Once thefirst gasket holder 851 is in the fill station 710, the access arm 870removes the gasket 475. The access arm 870 removes the gasket 475 fromthe fill station 710 and places the gasket 475 on the gasket pallet 560on the second conveyor 570. Another gasket 475 may then be placed withinthe fill station 710 and the process is repeated as described above.

[0081] The fill and cure station 150 may use optical or other types ofsensors to indicate when the molds 260, 280 are fill. These sensors maybe used as a secondary or a primary indicator of complete fill. If thesensors are used as a secondary indicator, the sensors may be a backupin case the molds 260, 280 somehow get assembled incorrectly, leading toan incorrect volume for the desired lens 110. A further method forfilling the gasket 475 with the polymeric lens material 780 is describedin U.S. patent application Ser. No. 09/026,277, entitled “Method andApparatus for Filling a Lens Forming Device with a Curable Fluid”, nowallowed and incorporated herein by reference. A further method forcuring the polymeric lens material 780 is described in U.S. patentapplication Ser. No. 09/026,222, entitled “Method for Curing a LensForming Fluid”, now allowed and incorporated herein by reference.

[0082] The Degasketing Station

[0083] The second conveyor 570 transports the gasket 475 along thepredetermined path P to the degasketing station 160. The degasketingstation 160 is shown in FIGS. 17-19. The degasketing station 160 mayinclude an extendable plunger 900 surrounded by a pair of movabledegasketing arms 910. The degasketing arms 910 may be movable towardsand away from the plunger 900 along a pair of rails 915 or a similartype of structure. Each degasketing arm 910 may have a pair of gripperarms 920 thereon so as to grab the gasket 475. The degasketing arms 910and the gripper arms 920 are operated by the control system 120. Thedegasketing station 160 also may include a first automated access arm950 and a second automated access arm 960. Both of the access arms 950,960 may be positioned on a gantry 970 for movement thereon along thepredetermined path P in a direction that may be perpendicular to thedirection of the second conveyor 570. The access arms 950, 960 mayfurther include an extendable cylinder 980 for vertical movement and apair of gripper arms 990 for horizontal movement. The access arms 950,960 are controlled by the control system 120.

[0084] The gripper arms 990 of the first access arm 950 may pick up thegasket 475 from the second conveyor 570 and place it on the plunger 900.The gripper arms 920 of the degasketing arms 910 then secure the gasket475 by grabbing it by the support brackets 650. The first access arm 950then returns to the second conveyor to pick up the next gasket 475. Thedegasketing arms 910 then retract away from the plunger 900 so as tostretch the gasket 475. Once the gasket 475 is stretched, the plunger900 rises so as to force the combined lens molds 260, 280 and the lens110 out of the gasket 475. The gripper arms 990 of the second access arm960 then grab the combined lens molds 260, 280 and the lens 110 andplace them on a finishing conveyor 1000 traveling along thepredetermined path P. The gasket 475 may then be removed, andpreferably, recycled.

[0085] The Demolding and Finishing Station

[0086] The finishing conveyor 1000 carries the combined molds 260, 280and the lens 110 to the demolding and finishing station 170. Thedemolding and finishing station 170 is shown in FIGS. 20-21. Thedemolding and finishing station 170 may include a housing 1010 with anumber of heating and cooling stations 1020 therein. The combined lensmolds 260, 280 and the lens 110 pass through the housing 1010 along thefinishing conveyor 1000 or another conveyor-type structure. Differencesin the thermal expansion characteristics of the molds 260, 280 and thelens 110 cause the lens 110 to separate from the mold 260, 280.

[0087] The lens 110 may then be removed and treated further in aconventional manner. Specifically, the lens 110 may be carried through ascratch coating stations 1030. The lens 110 may be dipped in a lacquertype coating that is thermally annealed to ensure bonding to the surfaceof the lens 110. Other coating methods or materials are also possible,such as spin, spray, or vacuum coating. Ultraviolet coating, chemicalvapor deposition coating, or plasma-applied coatings also are possible.The lens 110 then may be transported to a verification station 1040. Asis shown in FIG. 22, the verification station optically verifies thatthe lens 110 matches the intended prescription. The verification station1040 includes both an optical scanner 1050 to verify the prescriptionand a barcode scanner 1060 to ensure that the correct lens 110 ispresent. The lens 110 may then be packed and shipped to the customer.

[0088] The molds 260, 280 may be removed from the finishing station 170and transported to a cleaning station 1070. The cleaning station 1070ensures that the lenses 260, 280 are free of any monomer residue orother contaminates. After cleaning, the molds 260, 280 may bereintroduced to the storage and retrieval station 130 for positioning onthe carousel 300 and reuse.

[0089] Example of Use

[0090] By way of example, a lens prescription may be entered into thecontrol system 120 via the keyboard 210 or via any other type ofconventional data input/output means. Based upon this prescription, thecontrol system 120 selects the appropriate lens molds 260, 280 anddetermines where on the storage carousel 300 these molds 260, 280 may belocated. The control system 120 also determines the size and shape ofthe lens 110, i.e., the lens center thickness in terms of the depth ofthe first mold lens 260 within the gasket 475 in relationship to thedepth of the second lens mold 280 within the gasket 475. The controlsystem 120 determines the front and rear mold machine axis, i.e., therequired positioning of the tic mark 265 as viewed by the optical device485 of the positioning station 450. The control system 120 thendetermines the fill rate profile for the polymeric lens material 780 inthe bore 610 in the fill and cure station 150 in terms of the start fillrate, the mid fill rate, and the end fill rate and in terms of speed andpercentage of volume for each. The total volume of material 780 neededto fill the bore 610 also is determined. The control system 120 thendetermines the start time for the front ultraviolet light source 790,the start time for the rear ultraviolet light source 800, the timing ofthe shutters 810, 820, and the cure time in seconds to cure the lens 110with the light sources 790, 800. With the given prescription, the lenscenter thickness may be about one (1) to about ten (10) millimeters, theamount of polymeric lens material 780 may be about 15 to 40 milliliters,and the time to cure the material 780 may be about 10 to 180 seconds.

[0091] The manufacturing information on each prescription is preferablylocated in the database 220 of the control system 120 and/or on theindicator 430 of each mold 260, 280. Alternatively, each manufacturingparameter for the lens 110 may be entered and set individually asneeded.

[0092] Based upon this information, the control station 120 activatesthe storage carousel 300 to align the mold storage location 340 with theaccess arm 350. The access arm 350 removes the appropriate lens mold 260from its storage location 340 and places it in the basin 270 on thepallet 240. This process is then repeated with the second lens mold 280.

[0093] The control system 120 then activates the conveyor system 230 tobring the pallet 240 to the pre-orient and print station 135. The accessarm 440 grasps the first lens mold 260 and removes it from the pallet240. The optical device 444 reads the indicator 430 on the lens mold 260to inform the control system 120 that the correct mold 260 is present.The optical device 444 also may obtain the manufacturing parameters fromthe indicator 430. The access arm 440 returns the first lens mold 260 tothe pallet 240 and then removes the second lens mold 280. The opticaldevice 444 again reads the indicator 430 thereon and informs the controlsystem 120 that the correct mold 280 is present. Again, the opticaldevice 444 also may obtain the manufacturing parameters from theindicator 430. One or more tic marks 265 may be present on the mold 280so as to determine the orientation of the mold 260 and the desiredamount of rotation. The optical device 444 may recognize the orientationof the tic marks 265. The gripper arms 443 of the access arm 440 thenmay rotate the second lens mold 280 to prepare it for printing. Theprinter 445 prints the further indicator 448 on the lens mold 280 in apredetermined location. The access arm 440 then returns the second lensmold 280 to the pallet 240.

[0094] The conveyor 230 then carries the pallet 240 to the positioningand assembly station 140. The lens molds 260, 280 may be identified viathe radio frequency tag 295 on the pallet 295. The first access arm 501grabs the first lens mold 260 and carries it to the positioning station450. The positioning stage 480 then rotates the lens mold 260 inaccordance with the detected tic mark 265 to its proper location. Thesecond access arm 502 then picks up the first lens mold 260 and carriesit to the assembly station 460. Meanwhile, the first access arm 501picks up the second lens 280 from the pallet 240 and carries it to thepositioning station 450 where it is also verified and properly rotatedinto position.

[0095] The assembly stage 495 lowers the first lens mold 260 within thegasket mount 490 while the third access arm 503 moves a gasket 475 fromthe gasket source 470 on to the gasket mount 490. The assembly stage 495pushes the first lens mold 260 into the proper position within thegasket 475 as determined by the control system 120. The third access arm503 removes the gasket 475 from the assembly station 460. The secondaccess arm 502 then travels to the positioning station 450 and picks upthe second lens mold 280. The second access arm 502 transports thesecond lens mold 280 onto the assembly stage 495. The assembly stage 495withdraws within the gasket mount 490 while the third access arm 503places the gasket 475 onto the gasket mount 490. The assembly stage 495pushes the second lens mold 280 into the gasket 475 to the depthdetermined by the control system 120. The third assembly arm 503 thenpicks up the gasket 475 and places it on the gasket pallet 560 on thesecond conveyor 570.

[0096] The second conveyor 570 carries the gasket 475 to the fill andcure station 150. The access arm 870 picks up the gasket 475 and placesit within one of the modules 700 of the fill station 710. The needle 750of the fill station 710 penetrates the septum 630 of the gasket 475. Theneedle 750 inserts the polymeric lens material 780 into the bore 610 ofthe gasket 475 at the varying fill rate determined by the control system120. Once the bore 610 has been filled with the predetermined volume ofmaterial 780, the needle 750 is withdrawn and the gasket 475 is placedin one of the cure stations 720, 730. The shutters 810, 820 are openedand closed as determined by the control system 120. The gasket 475 issubject to the ultraviolet radiation for the predetermined amount oftime so as to form the lens 110. The further indicator 448 transfers tothe lens 110 in the curing process. The access arm 870 then removes thegasket 475 from the fill station 710 and places the gasket 475 on thegasket pallet 560 on the second conveyor 570.

[0097] The second conveyor 570 transports the gasket 475 to thedegasketing station 160. The first access arm 950 picks up the gasket475 from the second conveyor 570 and places it on the plunger 900. Thedegasketing arms 910 secure the gasket 475 along the support brackets650. The degasketing arms 910 stretch the gasket 475 while the plunger900 forces the lens 110 and the molds 260, 280 out of the gasket 475.The second access arm 960 then grabs the combined lens 110 and the molds260, 280 and places them on the finishing conveyor 1000.

[0098] The finishing conveyor 1000 carries the combined lens 110 and themolds 260, 280 to the demolding and finishing station 170. The finishingstation 170 separates the lens 110 and the mold 260, 280 by a number ofheating and cooling stations 1020. The lens 110 may then be separatedfrom the molds 260, 280 and further treated in a conventional manner.This treatment may include surface bonding, cleaning, coating, opticalverification, and shipping. The molds 260, 280 are removed and sentthrough the cleaning station 1070. The molds 260, 280 are thenreintroduced to the storage and retrieval station 130 for further use.

[0099] Given the method and apparatus of the present invention, the lens110 may be produced in about fifteen (15) to about forty-five (45)minutes. This includes the time from the point at which the controlsystem 120 activates the storage and retrieval station 130 until thepoint the lens 110 emerges from the heating and cooling stations 1020 ofthe finishing station 170. In continuing use, the system 100 of thepresent invention may produce about 300 to 400 lenses 110 an hour. Thesystem 100 may be able to produce two to ten million differentprescriptions or more.

[0100] It should be apparent that the foregoing relates only to thepreferred embodiments of the present invention and that numerous changesand modifications may be made herein without departing from the spiritand scope of the invention as defined by the following

We claim:
 1. An apparatus for manufacturing a lens with a predeterminedprescription from a plurality of lens molds, a gasket, and a source of afluid material, said apparatus comprising: a means for selecting a firstlens mold and a second lens mold from said plurality of lens molds basedupon said predetermined prescription; a means for positioning said firstlens mold and said second lens mold within said gasket based upon saidpredetermined prescription; a means for inserting a predetermined amountof said fluid material within said gasket and between said first lensmold and said second lens mold based upon said predeterminedprescription; a means for curing said fluid material so as to form saidlens based upon said predetermined prescription; and a means foradvancing said first lens mold and said second lens mold along apredetermined path through said selecting means, said positioning means,said fill means, and said cure means.
 2. The apparatus of claim 1,further comprising a control system for operating said selecting means,said positioning means, said fill means, and said cure means.
 3. Theapparatus of claim 2, wherein said control system comprises a personalcomputer.
 4. The apparatus of claim 2, wherein said control systemcomprises a database.
 5. The apparatus of claim 2, wherein said controlsystem comprises a means for input and output of data.
 6. The apparatusof claim 2, wherein said selecting means comprises a conveyor advancingalong said predetermined path.
 7. The apparatus of claim 6, wherein saidselecting means comprises one or more transport pallets positioned alongsaid conveyor.
 8. The apparatus of claim 7, wherein said selecting meanscomprises a storage carousel for storing said plurality of lens molds.9. The apparatus of claim 8, wherein said selecting means comprises anautomated access arm for transporting said first lens mold and saidsecond lens mold from said storage carousel to said pallet.
 10. Theapparatus of claim 9, wherein said access arm comprises a gantry formovement thereon.
 11. The apparatus of claim 9, wherein said access armcomprises a plurality of gripper heads.
 12. The apparatus of claim 11,wherein each of said plurality of gripper heads comprises a plurality ofgripper arms for gripping said first lens mold and said second lensmold.
 13. The apparatus of claim 11, wherein each of said plurality ofgripper heads comprises an optical device.
 14. The apparatus of claim13, wherein said optical device comprises a fiber optic sensor.
 15. Theapparatus of claim 2, wherein said positioning means comprises apositioning station.
 16. The apparatus of claim 15, wherein saidpositioning station comprises an optical device and wherein each of saidplurality of lens molds comprises a tic mark positioned thereon fordetection by said optical device.
 17. The apparatus of claim 16, whereinsaid optical device comprises a camera-based vision system.
 18. Theapparatus of claim 16, wherein said positioning station comprises apositioning stage for rotating said first lens mold and said second lensmold according to said tic mark.
 19. The apparatus of claim 15, whereinsaid positioning means comprises an assembly station.
 20. The apparatusof claim 19, wherein said assembly station comprises a retractableassembly stage such that said assembly stage can insert said first lensmold within said gasket at a first predetermined depth and insert saidsecond lens mold within said gasket at a second predetermined depth. 21.The apparatus of claim 19, wherein said assembly station comprises agasket mount positioned about said assembly stage.
 22. The apparatus ofclaim 19, wherein said positioning means comprises a gasket supply witha plurality of said gaskets.
 23. The apparatus of claim 22, wherein saidpositioning means comprises one or more access arms for maneuvering saidfirst lens mold, said second lens mold, and said gasket therethrough.24. The apparatus of claim 23, wherein said one or more access armscomprise a first access arm for positioning said first lens mold andsaid second lens mold on said positioning station, a second access armfor maneuvering said first lens mold and said second lens mold betweensaid positioning station and said assembly station, and a third accessarm for maneuvering said gasket between said gasket supply and saidassembly station and for removing said first lens mold, said second lensmold, and said gasket from said assembly station.
 25. The apparatus ofclaim 23, wherein said one or more access arms comprise a gantry formovement thereon.
 26. The apparatus of claim 23, wherein said one ormore access arms comprise a pair of gripper arms for gripping said firstlens mold, said second lens mold, and said gasket.
 27. The apparatus ofclaim 2, wherein said inserting means comprises one or more fillstations.
 28. The apparatus of claim 27, wherein said one or more fillstations comprise a needle for piercing said gasket.
 29. The apparatusof claim 27, wherein said one or more fill stations comprise a pump incommunication with said source of fluid material and said gasket. 30.The apparatus of claim 29, wherein said pump comprises a variable speedpump such that said pump supplies said fluid material to said gasket atmultiple rates.
 31. The apparatus of claim 27, wherein said insertingmeans comprises one or more access arms.
 32. The apparatus of claim 2,wherein said cure means comprises one or more cure stations.
 33. Theapparatus of claim 32, wherein said one or more cure stations compriseone or more radiation sources.
 34. The apparatus of claim 33, whereinsaid one or more radiation sources comprise one or more ultraviolet orvisible light sources.
 35. The apparatus of claim 34, wherein said oneor more radiation sources comprise a first radiation source and a secondradiation source.
 36. The apparatus of claim 33, wherein said one ormore radiation sources comprise one or more shutters.
 37. The apparatusof claim 36, wherein said one or more shutters comprise a first shutterand a second shutter and wherein said control system operates said firstshutter and said second shutter independently of one another.
 38. Theapparatus of claim 2, further comprising a means for identifying saidfirst lens mold and said second lens mold.
 39. The apparatus of claim38, wherein said identifying means comprises an access arm positionedalong said predetermined path to grasp said first lens mold and saidsecond lens mold.
 40. The apparatus of claim 39, wherein said first lensmold and said second lens mold each comprise an indicator thereon andwherein said identifying means comprises an optical device so as to readsaid indicator.
 41. The apparatus of claim 40, wherein said opticaldevice comprises a bar code reader.
 42. The apparatus of claim 39,wherein said first lens mold and said second lens mold each comprise oneor more tic marks, said one or more tic marks indicating the orientationof said first lens mold and said second lens mold, and wherein saidoptical device comprises a camera-based vision system such that saidoptical device can determine the orientation of said first lens mold andsaid second mold.
 43. The apparatus of claim 42, wherein said access armcomprises one or more gripper arms such that said gripper arms can graspsaid first lens mold and said second lens mold and also rotate saidfirst lens mold and said second lens mold.
 44. The apparatus of claim39, wherein said access arm comprises a printer thereon so as to print afurther indicator on said first lens mold or said second lens mold. 45.The apparatus of claim 2, further comprising a means for removing saidlens and said first lens mold and said second lens mold from saidgasket, said removing means positioned along said predetermined path.46. The apparatus of claim 45, wherein said removing means comprises apair of movable degasketing arms, said pair of movable degasketing armscapable of grabbing and stretching said gasket.
 47. The apparatus ofclaim 46, wherein said removing means comprises an extendable plunger,said extendable plunger capable of pushing said lens and said first lensmold and said second lens mold out of said gasket.
 48. The apparatus ofclaim 47, wherein said removing means comprises one or more access armsfor placing said gasket with said lens, said first lens mold, and saidsecond lens mold therein on said plunger and for removing said lens,said first lens mold, and said second lens mold from said plunger. 49.The apparatus of claim 2, further comprising a means for separating saidlens, said first lens mold, and said second lens mold.
 50. The apparatusof claim 49, wherein said separating means comprises a plurality ofheating and cooling stations.
 51. The apparatus of claim 1, furthercomprising a means for coating said lens with a scratch resistanttreatment.
 52. The apparatus of claim 1, further comprising a means forverifying said predetermined prescription of said lens.
 53. Theapparatus of claim 1, further comprising a means for cleaning said firstand second lens molds.
 54. A method for manufacturing a lens with apredetermined prescription from a plurality of lens molds, a gasket, anda source of a fluid material, said method comprising the steps of:selecting a first mold and a second mold from said plurality of lensmolds based upon said predetermined prescription; advancing said firstlens mold along a predetermined path; positioning said first lens moldwithin said gasket based upon said predetermined prescription; advancingsaid second lens mold along said predetermined path; positioning saidsecond lens mold within said gasket based upon said predeterminedprescription; advancing said first lens mold, said second lens mold, andsaid gasket along said predetermined path; inserting a predeterminedamount of said fluid material within said gasket and between said firstlens mold and said second lens mold based upon said predeterminedprescription; and curing said fluid material so as to form said lensbased upon said predetermined prescription.
 55. A storage and retrievalstation for use with a plurality of lens molds for making lenses,comprising: a control system; a conveyor controlled by said controlsystem; a storage rack for storing said plurality of the lens moldspositioned adjacent to said conveyor; and an access arm controlled bysaid control system for transporting a predetermined lens mold from saidplurality of lens molds on said storage rack to said conveyor; saidaccess arm comprising an optical device thereon so as to confirm thatsaid access arm has picked up one of said plurality of said lens moldfrom said storage rack.
 56. The storage and retrieval station of claim55, wherein said storage rack comprises a rotatable storage carousel.57. The storage and retrieval station of claim 56, wherein said controlsystem controls said rotatable storage carousel in coordination withsaid access arm.
 58. The storage and retrieval station of claim 55,wherein said access arm comprises a gantry for movement thereon.
 59. Thestorage and retrieval station of claim 58, wherein said access armcomprises a gripper head for rotation about said gantry.
 60. The storageand retrieval station of claim 59, wherein said gripper head comprises apair of gripper arms so as to acquire said predetermined lens mold. 61.The storage and retrieval station of claim 55, wherein said opticaldevice comprises a fiber optic sensor.
 62. An assembly apparatus forpositioning a first lens mold and a second lens mold into a gasket so asto form a lens of a predetermined prescription, said first and saidsecond lens molds each comprising a positioning mark thereon,comprising: a positioning station positioned along a predetermined pathfor observing said positioning mark on said first lens mold and saidsecond lens mold; a gasket supply with said gasket therein positionedalong said predetermined path to supply said gasket; an assembly stationpositioned along said predetermined path to position said first lensmold and said second lens mold within said gasket; and an access armsystem for transporting said first lens mold, said second lens mold, andsaid gasket along said predetermined path.
 63. The assembly apparatus ofclaim 62, further comprising a control system for operating saidpositioning station, said assembly station, and said access arm system.64. The assembly apparatus of claim 63, wherein said positioning stationcomprises an optical device for observing said positioning mark on saidfirst lens mold and said second lens mold.
 65. The assembly apparatus ofclaim 64, wherein said optical device comprises a camera-based visionsystem.
 66. The assembly apparatus of claim 64, wherein said positioningstation comprises a positioning stage surrounding said optical device.67. The assembly apparatus of claim 66, wherein said positioning stationrotates said first lens mold and said second lens mold as directed bysaid control system based upon said positioning mark.
 68. The assemblyapparatus of claim 63, wherein said assembly station comprises a gasketmount sized to support said gasket.
 69. The assembly apparatus of claim68, wherein said assembly station comprises an assembly stage positionedwithin said gasket mount, said assembly stage positioning said firstlens mold and said second lens mold into said gasket at a depth asdetermined by said control system based upon said predeterminedprescription.
 70. The assembly apparatus of claim 63, wherein saidaccess arm system comprises a gantry.
 71. The assembly apparatus ofclaim 70, wherein said access arm system comprises a plurality of accessarms positioned on said gantry from movement thereon.
 72. The assemblyapparatus of claim 71, wherein said plurality of access arms comprise afirst access arm for positioning said first lens mold and said secondlens mold on said positioning station, a second access arm formaneuvering said first lens mold and said second lens mold between saidpositioning station and said assembly station, and a third access armfor maneuvering said gasket between said gasket supply and said assemblystation and for removing said first lens mold, said second lens mold,and said gasket from said assembly station.
 73. The assembly apparatusof claim 71, wherein each of said plurality of access arms comprises aplurality of gripper arms to grip said first lens mold, said second lensmold, and said gasket.
 74. A device for filling a mold with a fluidmaterial and curing said fluid material, said device comprising: a fillstation; said fill station comprising a pump for delivering said fluidmaterial to said mold; said fill station comprising an insertion devicefor inserting said fluid material within said mold; and a cure station;said cure station comprising a plurality of light sources; and said curestation comprising a plurality of shutters, each of said plurality ofshutters positioned over one of said plurality of light sources and eachof said plurality of shutters operating independently of one another.75. The device for filling a mold of claim 74, further comprising acontrol system for controlling said fill station and said cure station.76. The device for filling a mold of claim 75, further comprising aplurality of cure stations.
 77. The device for filling a mold of claim75, wherein said insertion device comprises a non-coring needle.
 78. Thedevice for filling a mold of claim 75, wherein said pump comprises apositive displacement pump.
 79. The device for filling a mold of claim75, wherein said pump comprises a multispeed pump.
 80. The device forfilling a mold of claim 75, wherein said plurality of light sourcescomprises a plurality of ultraviolet light sources or a plurality ofvisible light sources.
 81. The device for filling a mold of claim 75,further comprising a movable bracket for maneuvering said mold betweensaid fill station and said cure station.
 82. A device for removing agasket from around a mold, said gasket comprising a plurality of supportbrackets, said device comprising: a plunger capable of movement in afirst direction; and a plurality of degasketing arms surrounding saidplunger, said plurality of degasketing arms capable of movement in asecond direction; said plurality of degasketing arms comprising aplurality of gripper arms to grip said support brackets of said gasketsuch that said plurality of degasketing arms stretch said gasket in saidsecond direction while said plunger forces said mold out of said gasketin said first direction.
 83. The device for removing a gasket of claim82, further comprising a control system for controlling said plunger,said plurality of degasketing arms, and said plurality of gripper arms.84. The device for removing a gasket of claim 82, further comprising anaccess arm for removing said mold from said plunger.
 85. A device foridentifying and orienting a lens mold, said lens mold advancing along aconveyor positioned along a predetermined path, said lens mold furthercomprising an identification indicator thereon and a positioning markthereon, said device comprising: an access arm positioned along saidpredetermined path to grasp said lens mold; an optical device positionedon said access arm so as to read said identification indicator and viewsaid positioning mark; and a printer positioned on said access arm toprint a further indicator on said lens mold on a predetermined locationthereon.
 86. The device of claim 85, further comprising a control systemfor controlling said access arm, said optical device, and said printer.87. The device of claim 86, wherein said optical device comprises a barcode reader to read said indicator.
 88. The device of claim 86, whereinoptical device comprises a camera-based vision system to view saidpositioning mark.
 89. The device of claim 88, wherein said access armcomprises one or more gripper arms such that said gripper arms can graspsaid lens mold and also rotate said lens mold.
 90. The apparatus ofclaim 86, wherein said printer comprises an ink jet printer.